Tubular string make-up methods utilizing image processing

ABSTRACT

A method of making-up tubular string components can include inputting to an image processor image data output from at least one camera, the image processor in response detecting positions of a tubular and a mark on another tubular, threading the tubulars with each other while inputting position data from the image processor to a controller, and the controller terminating the threading in response to the position of the mark relative to the position of the first tubular being within a predetermined range. Another method of making-up tubular string components can include, in response to inputting image data to an image processor, the image processor detecting longitudinal positions of two tubulars, threading the tubulars with each other, and a controller terminating the threading in response to the longitudinal position of one tubular relative to the longitudinal position of the other tubular being within a predetermined range.

BACKGROUND

This disclosure relates generally to equipment utilized and operationsperformed in conjunction with a subterranean well and, in certainexamples described below, more particularly provides for utilization ofimage processing in tubular string make-up operations.

Various types of tubular components can be threaded together to formtubular strings for use in a well. Tubulars used in wells can includeprotective wellbore linings (such as, casing, liner, etc.), productionor injection conduits (such as, production tubing, injection tubing,screens, etc.), drill pipe and drill collars, and associated components(such as tubular couplings).

It is typically important for threaded connections between tubulars tobe properly made-up. For example, when a threaded connection is properlymade-up, the threaded connection may prevent leakage of fluid into orout of the tubular string, or may resist unthreading of the connection.

It will, therefore, be readily appreciated that improvements arecontinually needed in the art of making-up threaded connections intubular strings. The present disclosure provides such improvements tothe art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative partially cross-sectional view of an exampleof a well system and associated method which can embody principles ofthis disclosure.

FIGS. 2A & B are representative side views of an example of the method,with a threaded connection in respective preliminary and made-upconfigurations.

FIGS. 3A & B are representative side views of another example of themethod, with a threaded connection in respective preliminary and made-upconfigurations.

FIGS. 4A & B are representative side views of another example of themethod, with a threaded connection in respective preliminary and made-upconfigurations.

FIGS. 5A & B are representative side views of another example of themethod, with a threaded connection in respective preliminary and made-upconfigurations.

FIGS. 6A-C are representative side views of threads in the FIGS. 5A & Bexample of the method, with thread starts of the threaded connection insuccessive azimuthally misaligned, azimuthally aligned and operativelyaligned configurations.

FIG. 7 is a representative schematic view of an example of a make-upcontrol system that may be used with the method examples of FIGS. 2A-6C.

DETAILED DESCRIPTION

Representatively illustrated in FIG. 1 is a system 10 for use with asubterranean well, and an associated method, which can embody principlesof this disclosure. However, it should be clearly understood that thesystem 10 and method are merely one example of an application of theprinciples of this disclosure in practice, and a wide variety of otherexamples are possible. Therefore, the scope of this disclosure is notlimited at all to the details of the system 10 and method describedherein and/or depicted in the drawings.

In the FIG. 1 example, a tubular string 12 is being assembled anddeployed into a well. The tubular string 12 in this example is aproduction or injection tubing string, but in other examples the tubularstring could be a casing, liner, drill pipe, completion, stimulation,testing or other type of tubular string. The scope of this disclosure isnot limited to use of any particular type of tubular string, or to anyparticular tubular components connected in a tubular string.

As depicted in FIG. 1, a tubular 14 is suspended near its upper end bymeans of a rotary table 16, which may comprise a pipe handling spiderand/or safety slips to grip the tubular 14 and support a weight of thetubular string 12. In this manner, the upper end of the tubular 14extends upwardly through a rig floor 18 in preparation for connectinganother tubular 20 to the tubular string 12.

In this example, a tubular coupling 22 is made-up to the upper end ofthe tubular 14 prior to the tubular 14 being connected in the tubularstring 12. The coupling 22 is internally threaded in each of itsopposite ends.

In conventional well operations, it is common for a threaded togethertubular and coupling to be referred to as a “joint” and for threadedtogether joints to be referred to as a “stand” of tubing, casing, liner,pipe, etc. However, in some examples, a separate coupling may not beused; instead one end (typically an upper “box” end of a joint) isinternally threaded and the other end (typically a lower “pin” end ofthe joint) is externally threaded, so that successive joints can bethreaded directly to each other.

Thus, the scope of this disclosure can encompass the use of a separatecoupling with a tubular, or the use of a tubular without a separatecoupling (in which case the coupling can be considered to be integrallyformed with, and a part of, the tubular). In the FIG. 1 example, thecoupling 22 can also be considered to be a tubular, since it is atubular component connected in the tubular string 12.

To make-up a threaded connection between the tubular 20 and the coupling22, a set of tongs or rotary and backup clamps 24, 26 are used. Therotary clamp 24 in the FIG. 1 example is used to grip, rotate and applytorque to the upper tubular 20 as it is threaded into the coupling 22.

The backup clamp 26 in the FIG. 1 example is used to grip and secure thelower tubular 14 against rotation, and to react the torque applied bythe rotary clamp 24. The rotary clamp 24 and the backup clamp 26 may beseparate devices, or they may be components of a rig apparatus known tothose skilled in the art as an “iron roughneck.”

In one example, the rotary clamp 24 and backup clamp 26 may becomponents of a tong system, such as the VERO™ tong system marketed byWeatherford International, Inc. of Houston, Tex. USA. In this example,the rotary clamp 24 may be a mechanism of the tong system that rotatesand applies torque to the upper tubular 20, and the backup clamp 26 maybe a backup mechanism of the tong system that reacts the applied torqueand prevents rotation of the lower tubular 14. Thus, the term “rotaryclamp” as used herein indicates the rotation and torque applicationmechanism, and the term “backup clamp” as used herein indicates thetorque reacting mechanism.

Note that it is not necessary for the tubulars 14, 20 (and coupling 22,if used) to be vertical in the tubular make-up operation. The tubulars14, 20 could instead be horizontal or otherwise oriented. Additionalsystems in which the principles of this disclosure may be incorporatedinclude the CAM™, COMCAM™ and TORKWRENCH™ bucking systems marketed byWeatherford International, Inc.

In other examples, a top drive (not shown) may be used to rotate andapply torque to the upper tubular 20. Thus, it will be appreciated thatthe scope of this disclosure is not limited to use of any particularequipment to grip, rotate, apply torque to, or react torque applied to,any tubular in a threaded connection make-up operation.

After the upper tubular 20 is properly made-up to the lower tubular 14or coupling 22, the tubular string 12 can be lowered further into thewell, and the make-up operation can be repeated to connect another standto the upper end of the tubular string. In this manner, the tubularstring 12 is progressively deployed into the well by connectingsuccessive stands to the upper end of the tubular string. In someexamples, an individual tubular component may be added to the tubularstring 12, instead of a stand.

In the FIG. 1 method, the threaded connection make-up process can becontrolled, so that a properly made-up connection is obtained, and thiscontrol can be automatic, so that human error is avoided. As describedmore fully below, at least one camera 28 can be used in certain examplesto facilitate this automatic control of the threaded connection make-upprocess.

As used herein, the term “camera” is used to indicate a device capableof obtaining images of an observed structure. Each image can comprise anarray or matrix of pixels, with each pixel having a combination ofoptical characteristics. Examples of cameras include digital videocameras, time of flight sensors and optical matrix sensors. Preferably,a camera does not contact a structure observed by the camera.

Referring additionally now to FIGS. 2A & B, a first example of themethod of making-up tubular string components is representativelyillustrated. For convenience, various examples of the method aredescribed below as they may be used with the system 10 of FIG. 1, butthe methods may be used with other systems in keeping with theprinciples of this disclosure.

As depicted in FIG. 2A, the threaded connection make-up process has beeninitiated. The tubular 20 is positioned above and axially aligned withthe coupling 22, with the rotary clamp 24 appropriately positioned togrip an outer surface of the tubular 20. The backup clamp 26 (seeFIG. 1) can grip an outer surface of the tubular 14 to react torqueapplied during the threaded connection make-up process.

A mark 30 is provided on the outer surface of the tubular 20 for use asan indicator of when a proper threaded connection has been achieved. Inthis example, the mark 30 is in the shape of a triangle having a basefacing toward the lower end of the tubular 20. The threaded connectionis properly made-up when the upper end of the coupling 22 is axially orlongitudinally aligned with the base of the triangle mark 30, or atleast within a predetermined distance range of the base of the trianglemark. In other examples, different shapes (such as, circles, lines,rectangles, etc.), alignments (such as, centered, adjacent, etc.) orpositions of marks may be used to indicate a properly made-up threadedconnection.

As depicted in FIG. 2A, multiple cameras 28 (only two of which arevisible in the drawing) are positioned about the tubular 20 and coupling22. In this example, the cameras 28 may be distributed circumferentiallyabout the tubular 20 and coupling 22, so that the mark 30 can beobserved by the cameras in all azimuthal positions of the mark,including when the tubular 20 is rotated by the rotary clamp 24 tomake-up the threaded connection. Any number of cameras 28 may be used.

While the tubular 20 is rotated by the rotary clamp 24, the cameras 28can observe the mark 30, including its longitudinal position relative tothe upper end of the coupling 22. The cameras 28 are connected to animage processor 54 (described more fully below, see FIG. 7), and theimage processor is capable of identifying or recognizing images of thecoupling 22 and mark 30 in image data output by the cameras.

Once the images of the coupling 22 and mark 30 are identified by theimage processor, the longitudinal distance between the positions of thecoupling and mark can be conveniently determined. A controller 52(described more fully below, see FIG. 7) receives position data from theimage processor and terminates the rotation of the tubular 20 by therotary clamp 24 when the threaded connection has been properly made-up.

Referring additionally now to FIG. 2B, the threaded connection isrepresentatively illustrated after the tubular 20 has been properlythreaded into the coupling 22. Note that the upper end of the coupling22 is now longitudinally aligned with the base of the triangle mark 30(or at least within a predetermined distance range of the base of thetriangle mark).

In the FIG. 2B example, the cameras 28 are able to rotate with thetubular 20 as it is threaded into the coupling 22, instead of being infixed positions about the tubular 20 and coupling 22. On the right-handside of FIG. 2B, one of the cameras 28 is attached to a rotor 32 of therotary clamp 24.

The rotor 32 is rotated by a motor (not shown) of the rotary clamp 24.Jaws 34 carried in the rotor 32 grip the outer surface of the tubular20, thereby transmitting torque from the rotor to the tubular as thetubular is threaded into the coupling 22. If a top drive is instead usedto rotate the tubular 20, then the rotor 32 could be a component of thetop drive mechanism that rotates with the tubular. The scope of thisdisclosure is not limited to use of any particular component to mount acamera so that the camera rotates with the tubular 20 while the threadedconnection is made-up.

On the left-hand side of FIG. 2B, one of the cameras 28 is attached toan aerial vehicle 36 (such as a drone). The controller mentioned aboveand described more fully below may be used to control a flight path ofthe aerial vehicle 36, so that the camera 28 can continuously observethe mark 30 and the coupling 22 while the tubular 20 is threaded intothe coupling. Thus, the camera 28 supported by the aerial vehicle 36will rotate with the tubular 20, and will observe the mark 30, as thethreaded connection is made-up.

Because each of the two cameras 28 in the FIG. 2B example can rotatewith the tubular 20 and continuously observe the mark 30 and thecoupling 22 while the threaded connection is made-up, it is notnecessary for multiple cameras to be used. However, multiple cameras 28can be used if desired, for example, to provide redundancy or for otherpurposes.

As described above, the controller 52 can terminate the threading of thetubular 20 into the coupling 22 when the position of the mark 30 (suchas a longitudinal position of the base of the mark) relative to theposition of the coupling 22 (such as a longitudinal position of an upperend of the coupling) is within a predetermined range. In some examples,additional conditions may need to be satisfied for the threadedconnection to be considered acceptable. Thus, the scope of thisdisclosure is not limited to use of only the relative positions of themark 30 and the coupling 22 to indicate a proper or acceptable threadedconnection.

For example, a minimum torque or range of torque values may need to beapplied to the threaded connection in order for the threaded connectionto be accepted or approved for use in the well. A sensor (such as atorque sensor of the rotary clamp 24, a top drive, a bucking unit or an“iron roughneck”) may be used to monitor the torque applied during thethreaded connection make-up process.

In the FIGS. 2A & B example, the method can include the steps of:

1. inputting image data to an image processor 54 (see FIG. 7), the imagedata being output from at least one camera 28;

2. in response to the inputting step, the image processor 54 detectingpositions of a threaded tubular (such as the coupling 22 or tubular 14)and a mark 30 on another threaded tubular 20;

3. threading together the tubular 20 and coupling 22;

4. during the threading step, inputting position data from the imageprocessor 54 to a controller 52 (see FIG. 7), the position data beingindicative of the position of the mark 30 relative to the position ofthe coupling 22; and

5. the controller 52 terminating the threading step in response to theposition of the mark 30 relative to the position of the coupling 22being within a predetermined range.

The controller 52 may terminate the threading step in response to alongitudinal distance between the positions of the coupling 22 and themark 30 being within the predetermined range, for example, in responseto the base of the mark 30 being longitudinally aligned with the upperend of the coupling 22 or within a predetermined longitudinal distanceof the upper end of the coupling.

The threading step may include rotating the tubular 20 relative to thecoupling 22. The camera 28 may rotate with the tubular 20 during thethreading step.

The method may include connecting the camera 28 to a rotor 32 used torotate the tubular 20, so that the camera 28 rotates with the rotor 32.The method may include connecting the camera 28 to an aerial vehicle 36.A flight path of the aerial vehicle 36 may be controlled by thecontroller 52 in response to the position data output from the imageprocessor 54.

Referring additionally now to FIGS. 3A & B, a second example of themethod of making-up tubular string components is representativelyillustrated. In this example, each of the tubular 20 and the coupling 22is provided with the mark 30 in the form of a longitudinally extendingline on its outer surface. The threaded connection is properly made-upwhen the marks 30 are azimuthally aligned (or within a predeterminedrange of such alignment) after the tubular 20 has shouldered up againstthe coupling 22.

The cameras 28 observe the marks 30 as the tubular 20 is threaded intothe coupling 22. Image data from the cameras 28 is input to the imageprocessor 54 in order to identify or recognize the azimuthal positionsof the marks 30 while the tubular 20 is threaded into the coupling 22.

A torque sensor (such as the torque sensor mentioned above formonitoring the torque applied during the threaded connection make-upprocess) may be connected to the controller 52 and used to determinewhen the tubular 20 has shouldered up against the coupling 22.Thereafter, when it is determined that the azimuthal positions of themarks 30 are aligned (or within a predetermined range of suchalignment), the controller 52 can terminate the rotation of the tubular20 by the rotary clamp 24.

As depicted in FIG. 3A, the tubular 20 is positioned above and axiallyaligned with the coupling 22 in preparation for initiating the threadedconnection make-up process. The cameras 28 observe the marks 30. Imagedata is output from the cameras 28 to the image processor 54, whichidentifies or recognizes the marks 30 and the azimuthal positions of themarks.

As depicted in FIG. 3B, the tubular 20 is rotated by the rotary clamp 24and is thereby threaded into the coupling 22 until at least twoconditions are satisfied: 1) the tubular 20 is shouldered up against thecoupling 22, and 2) after shouldering up, the marks 30 are azimuthallyaligned with each other (or within a predetermined range of suchalignment). When these conditions are satisfied, the controller 52terminates the rotation of the tubular 20 by the rotary clamp 24.

Note that the cameras 28 illustrated in FIG. 3A are in fixed positionsrelative to the tubular 20 and the coupling 22, and the camerasillustrated in FIG. 3B are rotatable with the tubular 20 relative to thecoupling. Any number, positions, displacement or arrangement of thecameras 28 may be used in the FIGS. 3A & B example in keeping with theprinciples of this disclosure.

In the FIGS. 3A & B example, the method can include the steps of:

1. inputting image data to an image processor 54 (see FIG. 7), the imagedata being output from at least one camera 28;

2. in response to the inputting step, the image processor 54 detectingpositions of a threaded tubular (such as the coupling 22 or tubular 14)and a mark 30 on another threaded tubular 20;

3. threading together the tubular 20 and coupling 22;

4. during the threading step, inputting position data from the imageprocessor 54 to a controller 52 (see FIG. 7), the position data beingindicative of the position of the mark 30 relative to the position ofthe coupling 22; and

5. the controller 52 terminating the threading step in response to theposition of the mark 30 relative to the position of the coupling 22being within a predetermined range.

The position of the coupling 22 may include an azimuthal position of amark 30 on the coupling 22, and the position of the mark 30 on thetubular 20 may include an azimuthal position of the mark 30 on thetubular 20.

The terminating step may include the controller 52 terminating thethreading in response to the azimuthal position of the mark 30 on thetubular 20 relative to the azimuthal position of the mark 30 on thecoupling 22 being within the predetermined range. The predeterminedrange may correspond to azimuthal alignment of the marks 30 on thecoupling 22 and the tubular 20.

The terminating step may include the controller 52 terminating thethreading in response to the azimuthal position of the mark 30 on thetubular 20 relative to the azimuthal position of the mark 30 on thecoupling 22 being within the predetermined range after the coupling 22and the tubular 20 are shouldered up.

Referring additionally now to FIGS. 4A & B, a third example of themethod of making-up tubular string components is representativelyillustrated. In this example, at least one camera 28 is used to observethe tubular 20 and the coupling 22, in order to determine when a desiredtotal thread loss TTL has been achieved as an indication of a properthreaded connection make-up.

Total thread loss TTL in this example is an axial length of the lowerend of the tubular 20 (which includes the external threads on thetubular) received in the coupling 22 during the threaded connectionmake-up process. As the tubular 20 is threaded into the coupling 22, thethreaded lower end of the tubular 20 is gradually received into theupper end of the coupling. In this example, the total thread loss TTLcorresponds to a longitudinal overlap of the first and second tubulars22, 20.

As depicted in FIG. 4A, the tubular 20 is positioned above and axiallyaligned with the coupling 22. The camera 28 observes the tubular 20 andthe coupling 22. Image data is output from the camera 28 to the imageprocessor 54, which identifies or recognizes the tubular 20 and thecoupling 22. Longitudinal positions of the lower end of the tubular 20and the upper end of the coupling 22 are determined.

Alternatively, relative longitudinal positions, or a longitudinaldistance between the positions of the lower end of the tubular 20 andthe upper end of the coupling 22, can be determined. As anotheralternative, the tubular 20 may be lowered until the longitudinalposition of the lower end of the tubular 20 is the same as thelongitudinal position of the upper end of the coupling 22, so that alongitudinal distance the tubular 20 is received into the coupling canbe computed from this reference point.

As depicted in FIG. 4B, the tubular 20 has been rotated by the rotaryclamp 24, so that the tubular 20 is threaded into the coupling 22. Thetotal thread loss TTL is now at a desired value, or within apredetermined range. The controller 52 terminates the rotation of thetubular 20 by the rotary clamp 24 when the desired total thread loss TTLis achieved, or when the TTL is within the predetermined range.

A sensor 38 (such as a position sensor, a proximity sensor, adisplacement sensor, etc.) may be used to measure longitudinaldisplacement of the tubular 20 as it is threaded into the coupling 22,in order to determine the TTL. For example, the longitudinal positionsof the lower end of the tubular 20 and the upper end of the coupling 22may be determined at the initiation of the threaded connection make-upprocess (see FIG. 4A), thereby allowing a calculation of the requireddownward longitudinal displacement of the tubular 20 required in orderto achieve the desired TTL. When the tubular 20 has displaced therequired longitudinal distance as it is threaded into the coupling 22(see FIG. 4B), the controller 52 can terminate the threaded connectionmake-up process by ceasing rotation of the tubular 20 by the rotaryclamp 24.

In the FIGS. 4A & B example, the method can include the steps of:

1. inputting image data to an image processor 54 (see FIG. 7), the imagedata being output from at least one camera 28;

2. in response to the inputting, the image processor 54 detectinglongitudinal positions of a coupling 22 (or other threaded tubular) andanother threaded tubular 20;

3. threading together the coupling 22 and the tubular 20;

4. inputting position data from the image processor 54 to a controller52 (see FIG. 7), the position data being indicative of the longitudinalposition of the tubular 20 relative to the longitudinal position of thecoupling 22; and

5. the controller 52 terminating the threading in response to thelongitudinal position of the tubular 20 relative to the longitudinalposition of the coupling 22 being within a predetermined range.

The predetermined range may comprise a desired total thread loss TTLbetween the tubulars 22, 20.

During the threading step, the longitudinal position of the tubular 20relative to the longitudinal position of the coupling 22 may include atotal thread loss TTL corresponding to a longitudinal overlap of thecoupling 22 and the tubular 20.

The longitudinal position of the coupling 22 may comprise a longitudinalposition of an end of the coupling 22, and the longitudinal position ofthe tubular 20 may comprise a longitudinal position of an end of thetubular 20.

The detecting step may include detecting when the longitudinal positionof the end of the tubular 20 is the same as the longitudinal position ofthe end of the coupling 22. After detecting when the longitudinalposition of the end of the tubular 20 is the same as the longitudinalposition of the end of the coupling 22, the detecting step may includedetecting a longitudinal displacement of the tubular 20 relative thecoupling 22. The terminating step may include terminating the threadingin response to the longitudinal displacement of the tubular 20 relativeto the coupling 22 being within the predetermined range.

Referring additionally now to FIGS. 5A & B, a fourth example of themethod of making-up tubular string components is representativelyillustrated. In this example, at least one camera 28 is used to observethe tubular 20 and the coupling 22, in order to determine when a desirednumber of rotations of the tubular 20 have been performed as anindication of a proper threaded connection make-up. The number ofrotations are counted after a thread start on the tubular 20 isoperatively aligned with a thread start on the coupling 22.

The camera 28 may be used to observe only the tubular 20 in order tomonitor rotation of the tubular 20. Alternatively, the camera 28 may beused to observe both of the tubular 20 and the coupling 22, for example,so that insertion of the tubular 20 into the coupling 22 can be detectedor confirmed, and then rotation of the tubular 20 relative to thecoupling can be monitored.

As depicted in FIG. 5A, the tubular 20 has been positioned above andaxially aligned with the coupling 22, and then the tubular 20 has beenlowered until the threads 40 on an exterior of the tubular 20 contactthe threads 42 on an interior of the coupling 22. As mentioned above,the camera 28 can be used to confirm that this insertion of the tubular20 into the coupling 22 has been accomplished.

At this point, the threads 40, 42 are contacting each other, but are notyet operatively threaded together. Confirmation that this contactbetween the threads 40, 42 has been achieved can be obtained bymonitoring a load cell measurement (such as a hook weight measurement ora top drive load cell measurement), which should show a decrease insupported load when the threads 40, 42 contact each other. This contactbetween the threads 40, 42 should occur after the insertion of thetubular 20 into the coupling 22 is confirmed as discussed above.

After the contact between the threads 40, 42 is confirmed, the tubular20 is rotated by the rotary clamp 24 in a rotary direction that isopposite to a rotary direction that will later be used to thread thetubular 20 into the coupling 22. For example, if the threads 40, 42 onthe tubular 20 and coupling 22 are right-hand threads, so that thetubular 20 will later be threaded into the coupling by rotating thetubular 20 in a clockwise direction as viewed from above, then thetubular 20 will initially be rotated in an opposite (counter-clockwise)direction. If the threads 40, 42 on the tubular 20 and coupling 22 areleft-hand threads, then the tubular 20 will initially be rotated in aclockwise direction. For convenience of description, it is assumedhereafter that the threads 40, 42 are right-hand threads, so that thetubular 20 is initially rotated in a counter-clockwise direction afterthe threads contact each other.

As the tubular 20 is rotated in the counter-clockwise direction, athread start on the tubular 20 will eventually be azimuthally alignedwith a thread start on the coupling 22. This azimuthal alignment willpermit some axially downward displacement of the tubular 20, so that thethreads 40, 42 are appropriately positioned for threading the tubular 20into the coupling 22.

When the thread starts become azimuthally aligned and the tubular 20displaces downward somewhat, the threads 40, 42 will again come intocontact with each other, which will produce a detectable vibration. Thisvibration can be measured using a sensor 44 (such as, an acousticsensor, an accelerometer, etc.). Alternatively, a displacement orposition sensor (such as the sensor 38, see FIG. 4B) may be used tomeasure the downward displacement of the tubular 20. The downwarddisplacement and vibration should occur after the tubular 20 is rotatedin the counter-clockwise direction in this example.

After the downward displacement and/or vibration is detected, thetubular 20 is rotated in an opposite rotary direction (clockwise in thisexample) by the rotary clamp 24, in order to thread the tubular 20 intothe coupling 22 as depicted in FIG. 5B. The camera 28 can be used toobserve the rotation of the tubular 20, so that a number of turns orrotations of the tubular can be measured. When it is determined that adesired number of turns or rotations have been achieved, the controllerwill terminate the rotation of the tubular 20 by the rotary clamp 24.

Alternatively, the tubular 20 may be rotated in the clockwise directionuntil a desired TTL is achieved, as described above for the FIGS. 4A & Bexample. As another alternative, the tubular 20 may be rotated in theclockwise direction until the tubular 20 shoulders up against thecoupling 22 and a desired torque is applied to the threaded connection.For example, the shouldering-up can be indicated by a substantialincrease in applied torque rate upon contact of the lower end of thetubular 20 with an annular shoulder 46 in the coupling 22.

Referring additionally now to FIGS. 6A-C, the threads 40, 42 on thetubular 20 and coupling 22 are representatively illustrated inconfigurations corresponding to the threaded connection make-up processdescribed above for the FIGS. 5A & B example. For convenience ofillustration and description, only the threads 40, 42 are depicted inFIGS. 6A-C. The external threads 40 on the tubular 20 are shown in solidlines, and the internal threads on the coupling 22 are shown in dashedlines.

As depicted in FIG. 6A, the threads 40, 42 are in contact with eachother, as described above with regard to FIG. 5A. Note that a threadstart 40 a of the threads 40 is not azimuthally aligned with a threadstart 42 a of the threads 42. At least a portion of a weight of thetubular 20 is supported by the contact between the threads 40, 42 in anarea azimuthally between the thread starts 40 a, 42 a.

As depicted in FIG. 6B, the tubular 20 has been rotated in thecounter-clockwise direction until the thread starts 40 a, 42 a areazimuthally aligned. At this point, the weight of the tubular 20 is nolonger supported by the contact between the threads 40, 42.

As depicted in FIG. 6C, the tubular 20 has displaced downward somewhat,until at least a portion of the weight of the tubular 20 is againsupported by contact between the threads 40, 42. This downwarddisplacement and/or vibration produced by the displacement and thencontact between the threads 40, 42 can be measured by the sensor 38and/or 44 as described above.

The threads 40, 42 are now operatively aligned for threading the tubular20 into the coupling 22. The tubular 20 can now be rotated in theclockwise direction by the rotary clamp 24 as described above in orderto make-up the threaded connection.

In the FIGS. 5A-6C example, the method can include the steps of:

1. supporting a threaded tubular (such as the coupling 22 and/or thetubular 14) relative to a rig floor 18 (see FIG. 1);

2. engaging a threaded tubular 20 with the coupling 22;

3. rotating the tubular 20 relative to the coupling 22 in a firstdirection, thereby producing a detectable vibration or longitudinaldisplacement when a thread start 40 a on the tubular 20 is azimuthallyaligned with a thread start 42 a on the coupling 22; and

4. then rotating the tubular 20 relative to the coupling 22 in a seconddirection opposite to the first direction, thereby threading togetherthe coupling 22 and the tubular 20.

The method may include inputting image data to an image processor 54(see FIG. 7), the image data being output from at least one camera 28;and in response to the inputting step, the image processor 54 detectingthe rotating of the tubular 20 relative to the coupling 22 in the seconddirection.

The method may include inputting rotation data from the image processor54 to a controller 52 (see FIG. 7), the rotation data being indicativeof a total rotation of the tubular 20 relative to the coupling 22 in thesecond direction; and the controller 52 terminating the threading inresponse to the total rotation of the tubular 20 relative to thecoupling 22 in the second direction being within a predetermined range.

The method may include a sensor 44 detecting the vibration produced whenthe thread start 40 a on the tubular 20 is azimuthally aligned with thethread start 42 a on the coupling 22.

The method may include a sensor 38 detecting the longitudinaldisplacement produced when the thread start 40 a on the tubular 20 isazimuthally aligned with the thread start 42 a on the coupling 22.

Referring additionally now to FIG. 7, a schematic view of an example ofa make-up control system 50 that may be used with the system 10 of FIG.1 and the method examples of FIGS. 2A-6C is representativelyillustrated. The make-up control system 50 may be used with othersystems and methods in keeping with the principles of this disclosure.

The make-up control system 50 includes a controller 52 for controllingoperation of various components of the system 10. In this example, thecontroller 52 is connected to the rotary clamp 24 for controllingrotation of the tubular 20. In examples described above, the controller52 can terminate or cease the rotation of the tubular 20 by the rotaryclamp 24 when a proper threaded connection has been achieved, forexample, to avoid over-torquing the threaded connection, to avoid humanerror, to achieve a greater level of efficiency, etc. The scope of thisdisclosure is not limited to any particular purpose or benefit obtainedby use of the controller 52 in the system 50.

The controller 52 can include various components designed to facilitatethe operation of the system 50. For example, the controller 52 mayinclude volatile and non-volatile memory (such as RAM, ROM, EPROM, ahard drive or solid state drive, etc.), a database and instructionsstored in the memory, data ports, input devices (such as a keyboard,keypad, touch screen, mouse, etc.), output devices (such as a monitor, aprinter, etc.), communication devices (such as a satellite link, a fiberoptic connection, a WiFi or Bluetooth transceiver, etc.), a computerprocessor, a programmable logic controller (PLC) or any other componentor combination of components. The scope of this disclosure is notlimited to any particular configuration, structure or capability of thecontroller 52.

As depicted in FIG. 7, at least one camera 28 is connected to an imageprocessor 54. The image processor 54 receives image data from the camera28 and, based on the image data, identifies or recognizes tubular stringcomponents (such as the tubular 20 and/or coupling 22) as represented inthe image data. In addition, the image processor 54 may be able toidentify or recognize movements of the tubular string components asrepresented in the image data.

The image processor 54 can include various components and capabilitiesdesigned to facilitate the identification or recognition of the tubularstring components and their movements. For example, the image processor54 may include neural or neuronal networks, fuzzy logic, artificialintelligence or other programmed capabilities that may be trained toidentify or recognize particular tubular string components. The imageprocessor 54 may include or comprise elements known to those skilled inthe art as an image processing engine, an image processing unit or animage signal processor. Techniques such as optical flow techniques maybe used to identify, recognize and quantify movements (such aslongitudinal displacements and/or rotations) of the tubular stringcomponents. The scope of this disclosure is not limited to anyparticular configuration, structure or capability of the image processor54.

The controller 52 may also receive outputs from various sensors of thesystem 10, such as the position or displacement sensor 38, the vibrationsensor 44, a sensor that measures torque applied to the threadedconnection, a sensor that measures hook weight, a load cell, etc. Anytype or combination of sensors may provide outputs to the controller 52in keeping with the principles of this disclosure.

The controller 52 may be in communication with the aerial vehicle 36,for example, via a wireless connection in the FIGS. 2B & 3B examples. Inthis manner, a flight path of the aerial vehicle 36 may be controlled bythe controller 52 in response to the position data output from the imageprocessor 54, so that the camera 28 supported by the aerial vehiclerotates with the tubular 20 as it is threaded into the coupling 22.

It may now be fully appreciated that the above disclosure providessignificant advancements to the art of making-up threaded connections intubular strings. In various examples described above, methods areprovided which produce properly made-up threaded connections in a mannerthat reduces or eliminates human error and improves efficiency of thethreaded connection make-up process.

More specifically, the above disclosure provides to the art a method ofmaking-up tubular string components for use in a subterranean well. Inone example, the method can include the steps of: inputting image datato an image processor 54, the image data being output from at least onecamera 28; in response to the inputting, the image processor 54detecting positions of a threaded first tubular (such as the coupling 22or tubular 14) and a mark 30 on a threaded second tubular 20; threadingthe first and second tubulars 22, 20 with each other; during thethreading, inputting position data from the image processor 54 to acontroller 52, the position data being indicative of the position of themark 30 relative to the position of the first tubular 22; and thecontroller 52 terminating the threading in response to the position ofthe mark 30 relative to the position of the first tubular 22 beingwithin a predetermined range.

The controller 52 may terminate the threading in response to alongitudinal distance between the positions of the first tubular 22 andthe mark 30 being within the predetermined range.

The threading may include rotating the second tubular 20 relative to thefirst tubular 22.

The camera 28 may rotate with the second tubular 20 during thethreading.

The method may include connecting the camera 28 to a rotor 32 used torotate the second tubular 20, so that the camera 28 rotates with therotor 32.

The method may include connecting the camera 28 to an aerial vehicle 36.A flight path of the aerial vehicle 36 may be controlled by thecontroller 52 in response to the position data output from the imageprocessor 54.

The position of the first tubular 22 may include an azimuthal positionof a mark 30 on the first tubular 22, and the position of the mark 30 onthe second tubular 20 may include an azimuthal position of the mark 30on the second tubular 20.

The terminating step may include the controller 52 terminating thethreading in response to the azimuthal position of the mark 30 on thesecond tubular 20 relative to the azimuthal position of the mark 30 onthe first tubular 22 being within the predetermined range.

The predetermined range may correspond to azimuthal alignment of themarks 30 on the first and second tubulars 22, 20.

The terminating step may include the controller 52 terminating thethreading in response to the azimuthal position of the mark 30 on thesecond tubular 20 relative to the azimuthal position of the mark 30 onthe first tubular 22 being within the predetermined range after thefirst and second tubulars 22, 20 are shouldered up.

The “at least one” camera 28 may comprise multiple cameras 28distributed circumferentially about the first and second tubulars 22,20.

Another method of making-up tubular string components for use in asubterranean well is provided to the art by the above disclosure. Inthis example, the method can include: inputting image data to an imageprocessor 54, the image data being output from at least one camera 28;in response to the inputting, the image processor 54 detectinglongitudinal positions of a threaded first tubular (such as the coupling22 and/or the tubular 14) and a threaded second tubular 20; threadingthe first and second tubulars 22, 20 with each other; inputting positiondata from the image processor 54 to a controller 52, the position databeing indicative of the longitudinal position of the second tubular 20relative to the longitudinal position of the first tubular 22; and thecontroller 52 terminating the threading in response to the longitudinalposition of the second tubular 20 relative to the longitudinal positionof the first tubular 22 being within a predetermined range.

During the threading step, the longitudinal position of the secondtubular 20 relative to the longitudinal position of the first tubular 22may include a total thread loss TTL corresponding to a longitudinaloverlap of the first and second tubulars 22, 20.

The predetermined range may comprise a desired total thread loss TTLbetween the first and second tubulars 22, 20.

The longitudinal position of the first tubular 22 may comprise alongitudinal position of an end of the first tubular 22, and thelongitudinal position of the second tubular 20 may comprise alongitudinal position of an end of the second tubular 20.

The detecting step may include detecting when the longitudinal positionof the end of the second tubular 20 is the same as the longitudinalposition of the end of the first tubular 22. After detecting when thelongitudinal position of the end of the second tubular 20 is the same asthe longitudinal position of the end of the first tubular 22, thedetecting step may include detecting a longitudinal displacement of thesecond tubular 20 relative the first tubular 22. The terminating stepmay include terminating the threading in response to the longitudinaldisplacement of the second tubular 20 relative to the first tubular 22being within the predetermined range.

Another method of making-up tubular string components for use in asubterranean well is described above. In this example, the method caninclude: supporting a threaded first tubular (such as the coupling 22and/or the tubular 14) relative to a rig floor 18; engaging a threadedsecond tubular 20 with the first tubular 22; rotating the second tubular20 relative to the first tubular 22 in a first direction, therebyproducing at least one of a detectable vibration and a longitudinaldisplacement, when a thread start 40 a on the second tubular 20 isazimuthally aligned with a thread start 42 a on the first tubular 22;and then rotating the second tubular 20 relative to the first tubular 22in a second direction opposite to the first direction, thereby threadingtogether the first and second tubulars 22, 20.

The method may include inputting image data to an image processor 54,the image data being output from at least one camera 28; and in responseto the inputting step, the image processor 54 detecting the rotating ofthe second tubular 20 relative to the first tubular 22 in the seconddirection.

The method may include inputting rotation data from the image processor54 to a controller 52, the rotation data being indicative of a totalrotation of the second tubular 20 relative to the first tubular 22 inthe second direction; and the controller 52 terminating the threading inresponse to the total rotation of the second tubular 20 relative to thefirst tubular 22 in the second direction being within a predeterminedrange.

The method may include a sensor 44 detecting the vibration, or a sensor38 detecting the longitudinal displacement, produced when the threadstart 40 a on the second tubular 20 is azimuthally aligned with thethread start 42 a on the first tubular 22.

Although various examples have been described above, with each examplehaving certain features, it should be understood that it is notnecessary for a particular feature of one example to be used exclusivelywith that example. Instead, any of the features described above and/ordepicted in the drawings can be combined with any of the examples, inaddition to or in substitution for any of the other features of thoseexamples. One example's features are not mutually exclusive to anotherexample's features. Instead, the scope of this disclosure encompassesany combination of any of the features.

Although each example described above includes a certain combination offeatures, it should be understood that it is not necessary for allfeatures of an example to be used. Instead, any of the featuresdescribed above can be used, without any other particular feature orfeatures also being used.

It should be understood that the various embodiments described hereinmay be utilized in various orientations and configurations, withoutdeparting from the principles of this disclosure. The embodiments aredescribed merely as examples of useful applications of the principles ofthe disclosure, which is not limited to any specific details of theseembodiments.

In the above description of the representative examples, directionalterms (such as “above,” “below,” “upper,” “lower,” “upward,” “downward,”etc.) are used for convenience in referring to the accompanyingdrawings. However, it should be clearly understood that the scope ofthis disclosure is not limited to any particular directions describedherein.

The terms “including,” “includes,” “comprising,” “comprises,” andsimilar terms are used in a non-limiting sense in this specification.For example, if a system, method, apparatus, device, etc., is describedas “including” a certain feature or element, the system, method,apparatus, device, etc., can include that feature or element, and canalso include other features or elements. Similarly, the term “comprises”is considered to mean “comprises, but is not limited to.”

Of course, a person skilled in the art would, upon a carefulconsideration of the above description of representative embodiments ofthe disclosure, readily appreciate that many modifications, additions,substitutions, deletions, and other changes may be made to the specificembodiments, and such changes are contemplated by the principles of thisdisclosure. For example, structures disclosed as being separately formedcan, in other examples, be integrally formed and vice versa.Accordingly, the foregoing detailed description is to be clearlyunderstood as being given by way of illustration and example only, thespirit and scope of the invention being limited solely by the appendedclaims and their equivalents.

What is claimed is:
 1. A method of making-up tubular string componentsfor use in a subterranean well, the method comprising: inputting imagedata to an image processor, the image data being output from at leastone camera; in response to the inputting, the image processor detectingpositions of a threaded first tubular and a mark on a threaded secondtubular; threading the first and second tubulars with each other; duringthe threading, inputting position data from the image processor to acontroller, the position data being indicative of the position of themark relative to the position of the first tubular; and the controllerterminating the threading in response to the position of the markrelative to the position of the first tubular being within apredetermined range.
 2. The method of claim 1, in which the controllerterminates the threading in response to a longitudinal distance betweenthe positions of the first tubular and the mark being within thepredetermined range.
 3. The method of claim 1, in which the threadingcomprises rotating the second tubular relative to the first tubular, andin which the camera rotates with the second tubular during thethreading.
 4. The method of claim 3, further comprising connecting thecamera to a rotor used to rotate the second tubular, whereby the camerarotates with the rotor.
 5. The method of claim 3, further comprisingconnecting the camera to an aerial vehicle, and a flight path of theaerial vehicle being controlled by the controller in response to theposition data input from the image processor.
 6. The method of claim 1,in which the position of the first tubular comprises an azimuthalposition of a mark on the first tubular, and the position of the mark onthe second tubular comprises an azimuthal position of the mark on thesecond tubular.
 7. The method of claim 6, in which the terminatingfurther comprises the controller terminating the threading in responseto the azimuthal position of the mark on the second tubular relative tothe azimuthal position of the mark on the first tubular being within thepredetermined range.
 8. The method of claim 7, in which thepredetermined range corresponds to azimuthal alignment of the marks onthe first and second tubulars.
 9. The method of claim 6, in which theterminating further comprises the controller terminating the threadingin response to the azimuthal position of the mark on the second tubularrelative to the azimuthal position of the mark on the first tubularbeing within the predetermined range after the first and second tubularsare shouldered up.
 10. The method of claim 1, in which the at least onecamera comprises multiple cameras distributed circumferentially aboutthe first and second tubulars.
 11. A method of making-up tubular stringcomponents for use in a subterranean well, the method comprising:inputting image data to an image processor, the image data being outputfrom at least one camera; in response to the inputting, the imageprocessor detecting longitudinal positions of a threaded first tubularand a threaded second tubular; threading the first and second tubularswith each other; inputting position data from the image processor to acontroller, the position data being indicative of the longitudinalposition of the second tubular relative to the longitudinal position ofthe first tubular; and the controller terminating the threading inresponse to the longitudinal position of the second tubular relative tothe longitudinal position of the first tubular being within apredetermined range.
 12. The method of claim 11, in which, during thethreading, the longitudinal position of the second tubular relative tothe longitudinal position of the first tubular comprises a total threadloss corresponding to a longitudinal overlap of the first and secondtubulars.
 13. The method of claim 11, in which the predetermined rangecomprises a desired total thread loss between the first and secondtubulars.
 14. The method of claim 11, in which the longitudinal positionof the first tubular comprises a longitudinal position of an end of thefirst tubular, and the longitudinal position of the second tubularcomprises a longitudinal position of an end of the second tubular. 15.The method of claim 14, in which the detecting further comprisesdetecting when the longitudinal position of the end of the secondtubular is the same as the longitudinal position of the end of the firsttubular.
 16. The method of claim 15, in which the detecting furthercomprises, after the detecting when the longitudinal position of the endof the second tubular is the same as the longitudinal position of theend of the first tubular, detecting a longitudinal displacement of thesecond tubular relative the first tubular, and in which the terminatingfurther comprises terminating the threading in response to thelongitudinal displacement of the second tubular relative to the firsttubular being within the predetermined range.
 17. A method of making-uptubular string components for use in a subterranean well, the methodcomprising: supporting a threaded first tubular relative to a rig floor;engaging a threaded second tubular with the first tubular; rotating thesecond tubular relative to the first tubular in a first direction,thereby producing at least one of a detectable vibration and alongitudinal displacement, when a thread start on the second tubular isazimuthally aligned with a thread start on the first tubular; and thenrotating the second tubular relative to the first tubular in a seconddirection opposite to the first direction, thereby threading togetherthe first and second tubulars.
 18. The method of claim 17, furthercomprising: inputting image data to an image processor, the image databeing output from at least one camera; and in response to the inputting,the image processor detecting the rotating of the second tubularrelative to the first tubular in the second direction.
 19. The method ofclaim 18, further comprising: inputting rotation data from the imageprocessor to a controller, the rotation data being indicative of a totalrotation of the second tubular relative to the first tubular in thesecond direction; and the controller terminating the threading inresponse to the total rotation of the second tubular relative to thefirst tubular in the second direction being within a predeterminedrange.
 20. The method of claim 17, further comprising a sensor detectingthe vibration produced when the thread start on the second tubular isazimuthally aligned with the thread start on the first tubular.
 21. Themethod of claim 17, further comprising a sensor detecting thelongitudinal displacement produced when the thread start on the secondtubular is azimuthally aligned with the thread start on the firsttubular.